Toxic gases and or flammable liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist for
a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing. Before
conducting any maintenance or servicing, consult with authorized
supervisor/manager.
All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any other language or computer language in
whole or in part, in any form or by any means, whether it be electronic, mechanical,
magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne
Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us free
from defects of material and of construction, and that our liability shall be limited to
replacing or repairing at our factory (without charge, except for transportation), or at
customer plant at our option, any material or construction in which defects become
apparent within one year from the date of shipment, except in cases where quotations or
acknowledgments provide for a shorter peri o d. C omponents manufactured by others bear
the warranty of their manufacturer. This warranty does not cover defects caused by wear,
accident, misuse, neglect or repairs other than those performed by Teledyne or an
authorized service center. We assume no liability for direct or indirect damages of any
kind and the purchaser by the acceptance of the equipment will assume all liability for
any damage which may result from its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our apparatus,
and to make any alterations in the dimensions, shape or weight of any parts, in so far as
such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, and serves as a tool by which
valuable data can be gathered. The information provided by the instrument may assist the
user in eliminating potential hazards caused by his process; however, it is essential that
all personnel involved in the use of the instrument or its interface, with the process being
measured, be properly trained in the process itself, as well as all instrumentation related
to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks,
labels, or redundancy, must be provided by the user or specifically requested of Teledyne
at the time the order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The
purchaser is responsible for the training of personnel, for providing hazard warning
methods and instrumentation per the appropriate standards, and for ensuring that hazard
warning devices and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments (TAI) cannot accept responsibility for conditions
beyond its knowledge and control. No statement expressed or implied by this document
or any information disseminated by the manufacturer or its agents, is to be construed as a
warranty of adequate safety control under the user’s process conditions.
ii Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer
Safety Messages
Your safety and the safety of others is very important. We have provided
many important safety messages in this manual. Please read these
messages carefully.
A safety message alerts you to potential hazards that could hurt you or
others. Each safety message is associated with a safety alert symbol. These
symbols are found in the manual and inside the instrument. The definition
of these symbols is described below:
GENERALWARNING/CAUTION: Refer to the instructions
for details on the specific danger. These cautions warn of
specific procedures which if not followed could cause bodily
Injury and/or damage the instrument.
CAUTION:HOT SURFACE WARNING:This warning is specific
to heated components within the instrument. Failure to heed the
warning could result in serious burns to skin and underlying
tissue.
WARNING:ELECTRICAL SHOCK HAZARD: Dangerous voltages
appear within this instrument. This warning is specific to an
electrical hazard existing at or nearby the component or
procedure under discussion. Failure to heed this warning could
result in injury and/or death from electrocution.
Technician Symbol: All operations marked with this symbol
are to be performed by qualified maintenance personnel only.
NOTE: Additional information and comments regarding a
specific component or procedure are highlighted in the form of
a note.
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN THIS
MANUAL.
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
Teledyne Analytical Instrumentsiii
Model 3010MA
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through the
installation, calibration and operation of your new analyzer. Please read
this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests. Please
check the front of this manual for any additional information in the form
of an Addendum which discusses specific information, procedures,
cautions and warnings that may be peculiar to your instrument.
Manuals do get lost. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
Figure 6-1: Side view of Paramagnetic Sensor ............................. 69
Figure 6-2: Front View of the Paramagnetic Sensor ...................... 69
Figure 6-3: Sensor and Trimpot Identification ................................ 70
Figure 6-4: 15-Pin Sensor Cable and Pin Identification ................. 72
Figure 6-5: Access to Temperature Controller in Control Unit ....... 74
Figure 6-6: Piping Diagram for Model 3010MA ............................. 77
Figure 6-7: Analysis Unit Front Panel ............................................ 77
Teledyne Analytical Instrumentsix
Model 3010MA
xTeledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Introduction
Preface
Overview
The Teledyne Analytical Instruments Model 3010MA Paramagnetic
Oxygen Purity Analyzer is a versatile microprocessor-based instrument for
analyzing the purity of an oxygen bearing gas stream. It is a “split
architecture” instrument designed for indoor use in non-hazardous areas.
The Control Unit contains the operator interface, electronics and display.
The Analysis Unit is a separate insulated and temperature controlled
enclosure which contains the oven, sensor, sample system and flowmeter.
The analyzer has three user settable ranges that encompass the complete
range of 0-100% oxygen. The ranges can be set to any convenient level
between 0 and 100% in one percent increments.
Note: The upper value of every range is non-adjustable and is fixed at
100% . The lower value can be adjusted anywhere from 99% to
0%.
Part I of this manual covers the Model 3010MA flush-panel and/or
rack-mount Control Unit. The Analysis Unit is covered in Part II of this
manual.
Typical Applications
A few typical applications of the Model 3010MA are:
• Monitoring inert gas blanketing
• Air separation and liquefaction
• Chemical reaction monitoring
• Semiconductor manufacturing
• Petrochemical process control
• Quality assurance
• Gas analysis certification.
Teledyne Analytical Instruments11
Part 1 Control Unit Model 3010MA
Main Features of the Analyzer
The Model 3010MA series Paramagnetic Oxygen Analyzers are
sophisticated yet simple to use. The main features of these analyzers
include:
• A 2-line alphanumeric display screen, driven by microprocessor
electronics, that continuously prompts and informs the operator.
• High resolution, accurate readings of oxygen content
• Paramagnetic oxygen sensor
• Microprocessor based electronics: 8-bit CMOS microprocessor
with 32 kB RAM and 128 kB ROM.
• Three user settable analysis ranges allow best match to users
process and equipment. Default setting are: 0-100%, 95-100%,
and 98-100% oxygen.
• Auto Ranging allows analyzer to automatically select the proper
preset range within the 0-100% range of the sensor. Manual
override allows the user to lock onto a specific range of interest.
• Two user-adjustable concentration alarms and a system failure
alarm.
• Self-diagnostic testing, at startup and on demand, with continuous
power-supply monitoring.
• Two way RFI protection.
• RS-232 serial digital port for use with a computer or other digital
communications device.
• Analog outputs for Concentration and Analysis Range: 0–1VDC
standard. Isolated 4–20 mA dc standard.
• Compact and versatile design—flush-panel, or rack-mountable
12 Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Introduction
OPERATING INSTRUCTIONS
Model 3010MA
Paramagnetic Oxygen Purity
Analyzer
Part I: Control Unit
Teledyne Analytical Instruments13
Part 1 Control Unit Model 3010MA
14Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Introduction
Introduction
1.1 Overview
The Teledyne Analytical Instruments Model 3010MA Paramagnetic
Oxygen Purity Analyzer is a versatile microprocessor-based instrument
for detecting the percentage of oxygen in a gas stream. This part of the
manual covers the Model 3010MA flush-panel and/or rack-mount Control
Unit. These units are for indoor use in a nonhazardous environment.
In addition to supplying the interface for operating and controlling
the analyzer, the Control Unit also houses:
Main circuit board
PID temperature controller
Pressure compensation circuitry
24VDC power supply for driving the Analysis Unit
Digital meter readout and display circuit board
Interface screen and circuit board
1.2 Front Panel (Operator Interface)
The standard 3010MA is housed in a rugged metal case with all
controls and displays accessible from the front panel. See Figure 1-1. The
front panel has thirteen buttons for operating the analyzer, a digital meter,
and an alphanumeric display.
Function Keys:
Six touch-sensitive membrane switches are used to change the
specific function performed by the analyzer:
• Analyze—Perform analysis for oxygen content of a sample gas.
• System—Perform system-related tasks (described in detail in
chapter 4, Operation.).
• Span—Span calibrate the analyzer.
• Zero—Zero calibrate the analyzer.
Teledyne Analytical Instruments15
Part 1 Control Unit Model 3010MA
• Alarms—Set the alarm setpoints and attributes.
• Range— Set up the 3 user definable ranges for the instrument.
Data Entry Keys:
Six touch-sensitive membrane switches are used to input data to the
instrument via the alphanumeric VFD display:
• Left & Right Arrows—Select between functions currently
displayed on the VFD screen.
• Up & Down Arrows—Increment or decrement values of
functions currently displayed.
• Enter—Moves VFD display on to the next screen in a series. If
none remains, returns to the Analyze screen.
• Escape—Moves VFD display back to the previous screen in a
series. If none remains, returns to the Analyze screen.
Digital Meter Display:
The meter display is a LED device that produces large, bright, 7segment numbers that are legible in any lighting environment. It produces
a continuous readout of oxygen concentration. It is accurate across all
ranges without the discontinuity inherent in analog range switching.
Alphanumeric Interface Screen:
The VFD screen is an easy-to-use interface from operator to analyzer.
It displays values, options, and messages that give the operator immediate
feedback.
Figure 1-1: Model 3010MA Control Unit Front Panel
16Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Introduction
Standby Button:
The Standby feature turns off the display and outputs, but circuitry is
still operating. It is useful for power saving as well as prolonging the life
of the display elements.
WARNING: THE INSTRUMENT IS STILL ENERGIZED WHEN THE
STANDBY BUTTON IS PRESSED.
THE POWER CABLE MUST BE UNPLUGGED TO
DISCONNECT POWER FROM THE INSTRUMENT.
WHEN CHASSIS IS EXPOSED OR WHEN ACCESS
DOOR IS OPEN AND POWER CABLE IS CONNECTED,
USE EXTRA CARE TO AVOID CONTACT WITH LIVE
ELECTRICAL CIRCUITS.
Access Door:
To provide access to the display circuitry, the PID temperature
controller or pressure compensation circuitry, the front panel swings open
when the latch in the upper right corner of the panel is pressed all the way
in with a narrow gauge tool. Accessing the main circuit board requires
unfastening the rear panel screws and sliding the unit out of the case.
1.3 Rear Panel (Equipment Interface)
The rear panel of the Model 3010MA Control Unit is shown in
Figure 1-2. Connections are made at this panel for power, RS-232
communication, equipment interfacing and connections to the Analysis
Unit. The connectors are described briefly here and in detail in the
Installation chapter of this manual.
• Power Connection— AC power source.
• Pressure In—1/8” Gas line input to pressure compensation
circuit from Analysis Unit.
Line voltage—Selector switch for line voltage 115/230.
• RS-232 Port—Serial digital concentration signal output and
control input.
• Sensor In Connector—15 pin D-connector sensor cable from
Analysis Unit, (includes 24VDC power)
• Heater Out— 7 pin CPC connector, Power to heater in Analysis
Unit
Teledyne Analytical Instruments17
Part 1 Control Unit Model 3010MA
• Network—For future expansion. Not implemented at this
Alarms—2 concentration and 1 system alarm
Analog Outputs—0-1VDC concentration and 0-1VDC
range ID. 4-20 mA concentration and optional 4-20 mA
range ID.
Remote Span/Zero—Digital inputs for external control of
analyzer calibration
Calibration Contact—Special contacts to signal that the
instrument is being calibrated and not monitoring sample
Range ID Contacts—Separate, dedicated range relay contacts
for low medium and high ranges
Figure 1-2 Rear Panel of Model 3010MA Control Unit
18Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Operational Theory
Operational Theory
2.1 Introduction
The analyzer is composed of three subsystems:
1. Paramagnetic Sensor
2. Sample System
3. Electronic Signal Processing, Display and Control
The paramagnetic sensor and the sample system are located in the
Analysis Unit while the Electronic Signal Processing, Display and Control
systems are housed in the Control Unit.
The sample system is designed to accept the sample gas and transport
it through the analyzer without contaminating or altering the sample prior
to analysis. It is described in detail in Part II Section 6.4 of this manual.
The Analysis Unit is separate from the Control Unit in order to
provide critical temperature stability. The paramagnetic sensor is an
electromechanical device that translates the amount of oxygen present in
the sample into an electrical signal. It is a partial pressure device sensitive
to both operating pressure (vent pressure) and temperature fluctuations.
The output from the sensor is compensated for pressure variation using a
baseline pressure initially set during calibration. Temperature at the sensor
is held constant using an 80 Watt heater controlled by a PID temperature
controller located in the Control Unit. Feedback from the sensor to the
PID controller is supplied by an RTD installed in the Analysis Unit. The
paramagnetic sensor is described in Part II Section 6.2.
The electronic signal processing, display and control subsystem
simplifies operation of the analyzer and accurately processes the sampled
data. The microprocessor controls all signal processing, input/output and
display functions for the analyzer. Figure 2-1 is a block diagram for the
Control Unit and Figure 2-2 is a block diagram for the Analysis Unit.
These diagrams indicate the functionality of each unit and the interaction
between them.
Teledyne Analytical Instruments19
Part 1 Control Unit Model 3010MA
Figure 2-1: Block Diagram for Model 3010MA Control Unit
Figure 2-2: Block Diagram for Model 3010MA Analysis Unit
20Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Operational Theory
2.2 Electronics and Signal Processing
The Model 3010MAParamagnetic Oxygen Purity Analyzer uses an
8031 microcontroller with 32 kB of RAM and 128 kB of ROM to control
all signal processing, input/output, and display functions for the analyzer.
System power is supplied from a universal power supply module designed
to be compatible with any international power source (Note: the heating
system for the analysis must be set to 115V or 230V with the line
voltage selector switch located on the rear Control unit).With the
exception of the paramagnetic sensor, all of the system electronics are
located in the Control Unit. Figure 2-3 shows the location of the
temperature controller and the main electronic PC boards.
Figure 2-3: Location of Electronic Components in Control Unit
The universal power supply is located behind the temperature
controller and is accessible after removing the rear panel.
The signal processing electronics including the microprocessor,
analog to digital, and digital to analog converters are located on the
motherboard at the bottom of the case. The preamplifier board is mounted
on top of the motherboard as shown in the above figure. These boards are
accessible after removing the rear panel. Figure 2-4 is a block diagram of
the analyzer electronics.
Teledyne Analytical Instruments21
Part 1 Control Unit Model 3010MA
When an oxygen level is present, the paramagnetic sensor in the
Analysis Unit generates a voltage in the range of 0 to 1VDC. The voltage
is passed to the Control Unit via the sensor cable between the Analysis
Unit and the Control Unit. A voltage amplifier in the Control Unit
conditions the signal and passes it to the 18-bit analog to digital (A/D)
converter which is controlled by the microprocessor.
The sensor’s vent pressure from the Analysis unit is received via a 1/8
inch gas connection on the rear of the control unit. The vent pressure is
then routed to the pressure transducer located on the pre-amp PCB. The
output from the sensor is condition by a two-stage amplifier and passed to
the A/D converter.
The concentration signal, pressure signal, and the input from the
control panel are processed by the microprocessor, and appropriate control
signals are directed to the display, alarms and communications port.
The same digital information is also sent to a 12 bit digital to analog
converter that produces the 4-20 mA dc and the 0-1VDC analog
concentration signal outputs, and the analog range ID outputs.
The microprocessor monitors the power supply, and activates the
system failure alarm if a malfunction is detected.
2.5 Temperature Control
For accurate analysis this instrument is temperature controlled to
provide a thermally stable environment. The analyzer must be brought to
thermal equilibrium prior to analyzing any sample gas. The paramagnetic
sensor is sensitive to operating temperature variations. The sensor module
used in the Model 3010MA includes a pre-amp and an internal
temperature controller set to 55C. The sensor module is also housed in an
insulated temperature controlled oven within the Analysis Unit to improve
thermal stability and isolate the system from any external temperature
fluctuation. The oven temperature is maintained at a constant 40C by the
PID temperature controller located in the Control Unit (see Figure 2-3).
Feedback to the temperature controller is by an RTDon the sensor
mounting block. The oven is capable of providing a maximum of 80
Watts.
22 Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Operational Theory
Figure 2-4: Block Diagram of the Model 3010MA Electronics
Teledyne Analytical Instruments23
Part 1 Control Unit Model 3010MA
24Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Installation
Installation
Installation of the Model 3010MA Analyzer includes:
1. Unpacking
2. Mounting
3. Gas connections
4. Electrical connections
5. Testing the system.
6. Initial Sensor Calibration
This chapter covers installation of the Control Unit. The Analysis
Unit installation is covered in Part II of this manual. Procedures for the
Initial Sensor Calibration is given in Part II Section 6.6.
3.1 Unpacking the Analyzer
The analyzer is shipped with all the materials you need to install and
prepare the system for operation. Carefully unpack the analyzer and
inspect it for damage. Immediately report any damage to the shipping
agent.
3.2 Mounting the Analyzer
The Model 3010MA is for indoor use in a general purpose area. It is
NOT for use in hazardous environments of any type.
The standard model is designed for flush panel mounting. There are
four mounting holes—one in each corner of the rigid frame. Anoutline
drawing D73635, is included in the Drawings section in the rear of this
manual which contains a panel cutout diagram.
On special order, a 19" rack-mounting version can be provided. For
rack mounting, the 3010MA Control Unit and Analysis Unit are flushpanel mounted side by side on the rack panel. Figure 3-1 is a drawing for a
typical 19 inch rack mounted Model 3010 MA.
Teledyne Analytical Instruments25
Part 1 Control Unit Model 3010MA
Figure 3-1: Rack Mountable Control and Analysis Units
26Teledyne Analytical Instruments
Paramagnetic O2 Purity Analyzer Installation
All operator controls are mounted on the control panel which is
shown in Figure 3-2. The panel is hinged on the left edge and doubles as a
door to provides access to the display electronics, PCB’s and temperature
controller inside the instrument. The door is spring loaded and will swing
open when the button in the center of the latch (upper right corner) is
pressed all the way in with a narrow gauge tool (less than 0.18 inch wide),
such as a small hex wrench or screwdriver Allow clearance for the door to
open in a 90-degree arc of radius 7.125 inches. See Figure 3-2.
Figure 3-2: Front Panel of the Model 3010MA
Figure 3-3: Required Front Door Clearance
Teledyne Analytical Instruments27
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